Windmill cable system and method

Abstract

An improved cable system and method for an electricity generating windmill having a base formed from a plurality of stacked base sections is provided. Each base section includes a bundle of both power and control cables which are alignable with one another when the base sections are stacked and assembled. Mating electrical connectors which may be easily interlocked are provided at the ends of the power and control cables, and in the terminals of the generator and inverter of the windmill. In the preferred embodiment, bayonet-type connectors are used to provide a secure, interlocking coupling between adjacent cable ends with a minimum amount of twisting motion between the cables, which are necessarily of heavy gauge to conduct the current produced by the generator. The system greatly facilitates installation of the cable system as well as repair or replacement of damaged or worn cables during the lifetime of the windmill.

1 . An improved cable system for an electricity generating windmill of a type having a base formed from a plurality of stacked base sections, wherein first and second base sections have first and second groups of power cables for conducting electricity generated by the windmill, and wherein ends of one group of power cables are adjacent to ends of another group of power cables or to a terminal of an electric device when said base sections are stacked, wherein the improvement comprises: 
 electrical connectors mounted on said ends of said one group of power cables that detachably couple to electrical connectors mounted on said adjacent ends of said another group of power cables or to electrical connectors mounted in said terminal of said electric device to form electrical connector assemblies between said groups of power cables or a group of power cables and said terminal.    
   
   
       2 . The system according to  claim 1 , wherein at least some of said electrical connectors forming said electrical connector assemblies are detachably coupled by a mechanical interference coupling.  
   
   
       3 . The system according to  claim 2 , wherein said electrical connectors forming said electrical connector assemblies are detachably coupled by a bayonet-type coupling that interlocks said electrical connectors together when they are mated and twisted relative to one another.  
   
   
       4 . The system according to  claim 3 , wherein said bayonet-type coupling includes a ratchet lock that prevents bayonet-type coupling from becoming detached after said electrical connectors forming said assembly are mated and twisted.  
   
   
       5 . The system according to  claim 3 , wherein said bayonet-type coupling interlocks said electrical connectors when said connectors are mated and each twisted no more than 45° with respect to each other.  
   
   
       6 . The system according to  claim 2 , wherein said mechanical interference coupling allows one electrical connector to rotate at least 15° with respect to another in response to torsional forces after said electrical connectors have been detachably coupled into electrical connector assemblies.  
   
   
       7 . The system according to  claim 1 , wherein said electrical connector assemblies include a waterproof sleeve.  
   
   
       8 . The system according to  claim 7 , wherein said waterproof sleeve includes first and second mating sleeves circumscribing first and second connectors respectively, that detachably join in a water tight seal.  
   
   
       9 . The system according to  claim 8 , wherein said mating sleeves are integrally formed from a same insulation material on an outside of said power cables.  
   
   
       10 . The system according to  claim 1 , wherein said power cables include a plurality of single strand metallic conductors, substantially all of which are helically wound in a same direction to provide torsional flexibility to the cable.  
   
   
       11 . An improved cable system for an electricity generating windmill of a type having a base formed from a plurality of stacked base sections, wherein first and second base sections have first and second groups of power cables for conducting electricity generated by the windmill, and wherein ends of one group of power cables are adjacent to ends of another group of power cables or to a terminal of an electric device when said base sections are stacked, wherein the improvement comprises: 
 electrical connectors mounted on said ends of said one group of power cables that detachably couple to electrical connectors mounted on said adjacent ends of said another group of power cables or to electrical connectors mounted in said terminal of an electric device to form electrical connector assemblies between said groups of power cables or a group of power cables and said terminal,    wherein said connectors include a conductive metal member, and at least some of said electrical connectors forming said electrical connector assemblies are detachably coupled by a mechanical interference coupling formed by interlocking portions of their conductive metal members.    
   
   
       12 . The system according to  claim 11 , wherein said electrical connectors forming said electrical connector assemblies are detachably coupled by a bayonet-type coupling that interlocks said electrical connectors together when they are mated and twisted relative to one another.  
   
   
       13 . The system according to  claim 12 , wherein said bayonet-type coupling includes a ratchet lock that prevents bayonet-type coupling from becoming detached after said electrical connectors forming said assembly are mated and twisted.  
   
   
       14 . The system according to  claim 12 , wherein said bayonet-type coupling interlocks said electrical connectors when said connectors are mated and each twisted no more than 45° with respect to each other.  
   
   
       15 . The system according to  claim 11 , wherein said mechanical interference coupling allows one electrical connector to rotate at least 20° with respect to another in response to torsional forces after said electrical connectors have been detachably coupled into electrical connector assemblies.  
   
   
       16 . The system according to  claim 11 , wherein said cables include a plurality of single strand metallic conductors, substantially all of which are helically wound in a same direction to provide torsional flexibility to the cable.  
   
   
       17 . The system according to  claim 11 , wherein said electrical connector assemblies include a waterproof sleeve.  
   
   
       18 . The system according to  claim 17 , wherein said waterproof sleeve includes first and second mating sleeves circumscribing first and second connectors respectively, that detachably join in a water tight seal.  
   
   
       19 . The system according to  claim 18 , wherein said mating sleeves are integrally formed from a same insulation material on an outside of said cables.  
   
   
       20 . The system according to  claim 11 , wherein said electrical device is one of an electrical generator and an inverter circuit.  
   
   
       21 . The system according to  claim 17 , wherein said sleeve includes a stress relief portion.  
   
   
       22 . The system according to  claim 11 , further comprising first and second groups of control cables for supplying power to control systems of said electrical generator, wherein first and second control cable groups are mounted on said first and second base sections and have ends that are adjacent one another and which include electrical connectors that are detachably connectable.  
   
   
       23 . The system according to  claim 11 , wherein said windmill has a head assembly that includes said generator and is oscillatingly mounted on a top end of said base.  
   
   
       24 . The system according to  claim 23 , wherein said groups of power cables includes a loop of said cables between said generator and a group of cables mounted on a top base section to accommodate oscillatory movement of the generator relative to the base.  
   
   
       25 . An improved method for installing a system of cables in an electricity generating windmill that conduct electricity generated by the windmill to an inverter circuit, wherein said windmill is of a type having a base formed from a plurality of stacked base sections, wherein first and second base sections have first and second groups of power cables for conducting electricity generated by the windmill, and wherein ends of one group of power cables are adjacent to ends of another group of cable or to a terminal of an electric device when said base sections are stacked, comprising the steps of 
 mounting electrical connectors on said ends of said groups of power cables and on said terminal that detachably couple to form electrical connector assemblies between said groups of power cables or a group of power cables and said terminal, and    detachably connecting said connectors together after said base sections are stacked.    
   
   
       26 . The method according to  claim 25 , wherein said electrical connectors are mounted on said ends of said groups of cables prior to stacking said base sections together.  
   
   
       27 . The method according to  claim 26 , wherein the electrical connectors on said group of cables are detachably coupled after said base sections are stacked together.  
   
   
       28 . The method according to  claim 25 , wherein said electrical connectors are detachably connected by a bayonet-type coupling between the connectors.